Bacharach HGM300, RDM800 User Manual
HGM300/RDM800 PREVENTATIVE MAINTENANCE AND TECHNICAL SUPPORT
SECTION 1 – HGM300 CPU reset, RDM800 CPU reset, WARM UP notes and HGM300 Self
Test
SECTION 2 - HGM300/RDM800 Mechanical Room layout
SECTION 3 – HGM300 Relay Connector
SECTION 4 – Flow check procedure
SECTION 5 – Clipping fault adjustment
SECTION 6 – Dual loop 4-20 mA dc scrolling output
SECTION 7 – HGM300 voltage check Dual loop 4-20 mA dc scrolling output
SECTION 8 – Alarm silencing
SECTION 9 - NDIR Sensor
SECTION 10 – Gas verification test procedures
A- Procedure with RDM800
B- Procedure with PC software
SECTION 11 – Password protection
SECTION 12 – Whom to call - Warranty
Rev 3/2/09
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SECTION 1
HGM300 / RDM800 TECHNICAL SUPPORT NOTES
HGM300 CPU RESET
Locate the white button marked “CPU reset” on the main HGM300 board (about the center of the main board).
Locate the second reset button to the left of the CPU reset button. Hold the left button in, press and release the CPU
reset button. There will be 5 beeps (beep/beep – beep/beep – beep). Release the left button. The monitor will now be
reset
A second way to reset the HGM300 CPU is to turn off power, press and hold the left hand reset button and re-apply
power – 5 beeps and release button.
RDM800 CPU RESET
Shut off power to the RDM800, press and hold the top right adjacent button and re-apply power – 5 beeps and
release button.
MONITOR WILL NOT COME OUT OF “WARM UP”
Try executing “SET HGM CLOCK” from RDM800. This has corrected the problem in a few instances.
TO BYPASS THE WARM UP MODE
Service mode – Going into and out of the service mode will perform the following functions;
1) – By pass the warm-up cycle
2) – Force a purge cycle
3) – Force a pressure check
This may be helpful in analyzing problems with the monitor.
HGM300 Self Test Mode
The HGM300 refrigerant monitor has a built in self-test mode that will test the following functions:
To start the self-test function, locate the left hand white button under the micro controller PCB marked
“SW1”. Press and hold for two seconds then release the button.
For version 1.0 and version 1.25 firmware HGM300 monitors –
All lights on the HGM300 go out.
The Yellow light on the RDM800 will come on after a few moments (Time out error).
Each light in succession (Green, Yellow and Red) will come on.
The monitor will toggle each relay (Leak, Spill, Evacuate and Fault) in succession.
A signal in both channels of the dual 4-20 mA loop will simultaneously be generated
(4 mA to 12 mA to 20 mA - Red light flashing).
The Red light will flash during the 4-20mA test, then all lights will go out and both the HGM300 and
RDM800 will return to green on only.
For version 1.40 and higher HGM300 monitors –
Prior to stepping through the functions listed for version 1.0 and 1.25 the HGM300 will complete a
solenoid valve check. So for V 1.40 you will hear each solenoid click before the lights sequence. The
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valve check starts at zone 16 and works down to the purge solenoid. A four zone monitor there is a
ten seconds of silence before the valves start to click.
All lights on the HGM300 go out.
The Yellow light on the RDM800 will come on after a few moments (Time out error).
Each light in succession (Green, Yellow and Red) will come on.
The monitor will toggle each relay (Leak, Spill, Evacuate and Fault) in succession.
A signal in both channels of the dual 4-20 mA loop will simultaneously be generated
(4 mA to 12 mA to 20 mA - Red light flashing).
The Red light will flash during the 4-20mA test, then all lights will go out, and both the HGM300
and RDM800 will return to “power on” green only.
COMMON RDM800 INDICATIONS
Initial start up of the HGM300/RDM800 system
TIME OUT ERROR – The TIME OUT ERROR indicates that the RDM800 has not gained
communication with the HGM300. Check for proper RS-485 connections in both the HGM300 and
RDM800. Check for detent at each key on the RDM800. (If a key is stuck on the chassis this could lock
out all functions). Locate the stuck key or keys and slip the extension back into the cut out in the chassis.
CRC ERROR (Cyclical Redundancy Check)
This indicates that the data from the HGM300 was corrupted in some manner. Reset the HGM300 and
RDM800 to factory default settings and reset both clocks.
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SECTION 2
HGM300/RDM800 Refrigerant Gas leak monitor mechanical room placement
Exhaust Fan
Aux. Horn/Strobe
Remote Alarm
Outside Hallway
Sample Inlet
Pickup Point
Chiller
Machine Room
RDM800
Remote
Display
Module
HGM300
Halogen Gas
Monitor
Sample Inlet Pickup Points
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SECTION 3
HGM300 Relay Connector
Alarm Alarm Alarm
1 2 3 Fault
Relay
#1
NO
COMMON
Strobe
Relay
NC
#2
NO
COMMON
Relay
NC
#3
NO
COMMON
Relay
NC
#4
NC
NO
COMMON
Horn
Aux. Power Main Power
Line
Neutral
Jumper the ‘Neutral’ of the auxiliary power connector to the ‘Common’ on the relay block.
Connect one end of strobe or horn to the ‘NO’ of whichever level of alarm is appropriate for application.
The other end of strobe or horn is connected to a 120VAC power source, or to the ‘Line’ of the auxiliary
power connector.
Rev 3/2/09
Line
Neutral
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SECTION 4
NO FLOW CHECK PROCEDURE
NO FLOW ZONE Check for air sample tube blockage.
NO FLOW PURGE Check for blockage of purge line. Verify that the purge line does not exceed 100’ in length.
NO FLOW ZONE AND NO FLOW PURGE Check the water trap. If full of water, drain and re-secure the
petcock. If there is no water in the trap, check for a blockage in the exhaust line. Verify that the exhaust line does
not exceed 100’ in length.
NOTE_ Go to the diagnostic screen and view the “PRESS”, “VAC” and “AMB” values. I “PRESS” equals “VAC”;
there is a blockage in the pneumatic system. If “PRESS”, “VAC” and “AMB” are all equal at about 14.0 PSIA then
there is a leak in the pneumatic system.
If “AMB” is below “PRESS”, disconnect the purge line and force a pressure check. If “AMB” is now correct the
problem is in the purge line.
Note – If the unit does not see all zones check the elbow fittings on the water trap. If they are cracked or broken the
monitor may see only 4 zones.
1) – Pinch off the tubing between the water trap and in line filter. Go to the diagnostic screen on the RDM800.
Observe the “PRES”, “VAC” AND “AMB” readings at the bottom of the screen.
a) – If the pressure DOES NOT drop to normal vacuum levels (about 2 PSIA below pressure reading) the
problem is in one of the following;
1) – Tubing from the filter to the “T” connector.
2) - Tubing from the “T” connector to pressure sensor.
3) – Tubing from “T” connector to the I/R bench.
4) – Tubing from I/R bench to the pump.
b) – If the pressure DOES drop to normal vacuum levels then go to the tubing between the solenoid manifold
and the water trap and pinch it closed.
1) – If the pressure DOES NOT drop to the same level as the first reading the problem is in the water
trap.
2) – If the pressure DOES drop to the same reading as the first reading the problem is most likely in
either the tubing around the solenoid manifolds or the solenoids themselves.
Rev 3/2/09
Observe “PRES”, “VAC”
and “AMB” readings during
the check procedure
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O
C
G
U
O
ADDITIONAL NOTES ON “NO FLOW” PROBLEMS (THE FLOW RATE OF THE PUMP IS 2L/MIN)
A DIFFERENCE OF LESS THEN 0.1 PSIA BETWEEN AMBIENT AND PRESSURE WILL CAUSE A “N0
FLOW” FAULT.
A VACUUM OF 0.7 PSIA OR LESS BELOW PRESSURE WILL CAUSE A “N0 FLOW” FAULT.
TO OBSERVE PRESSURE READINGS ON THE DIAGNOSTIC SCREEN ZONE BY ZONE, YOU MUST
PUT A ZONE INTO”ZONE HOLD” THEN GO TO THE DIAGNOSTIC SCREEN AND VERFY THAT
YOU ARE OBSERVING THE PROPER ZONE AT THE TOP OF THE SCREEN.
IN LINE FILTER
“T” CONNECTOR PRESSURE SENSOR
I/R BENCH
SOLENOID
MANIF
LD
STEP”A”
H TUBIN
PIN
STEP “B” PINCH
BING HERE
T
EXHAUST
PUMP
ENSURE THAT DRAIN
PETCOCK IS TIGHT
(TURN CLOCKWISE TO
TIGHTEN
WATER TRAP
CHECK THAT
AT” IS FREE
“FL
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